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This work mainly focuses on increasing the mechanical strength and improving the corrosion resistance of an aluminum alloy hybrid matrix. The composites are prepared by the stir casting procedure. For this work, aluminum alloy 8079 is considered as a base material and titanium nitride and zirconium dioxide are utilized as reinforcement particles. Mechanical tests, such as the ultimate tensile strength, wear, salt spray corrosion test and microhardness test, are conducted effectively in the fabricated AA8079/TiN + ZrO2 composites. L9 OA statistical analysis is executed to optimize the process parameters of the mechanical and corrosion tests. ANOVA analysis defines the contribution and influence of each parameter. In the tensile and wear test, parameters are chosen as % of reinforcement (3%, 6% and 9%), stirring speed (500, 550 and 600 rpm) and stirring time (20, 25 and 30 min). Similarly, in the salt spray test and microhardness test, the selected parameters are: percentage of reinforcement (3%, 6% and 9%), pH value (3, 6 and 9), and hang time (24, 48 and 72 h). The percentage of reinforcement highly influenced the wear and microhardness test, while the stirring time parameter extremely influenced the ultimate tensile strength. From the corrosion test, the hang time influences the corrosion rate. The SEM analysis highly reveals the bonding of each reinforcement particle to the base material. [ABSTRACT FROM AUTHOR]

With the advent of the industrial revolution 4.0, the goal of the manufacturing industry is to produce a large number of products in relatively less time. This study applies the Taguchi L27 orthogonal array methodological paradigm along with response surface design. This work optimizes the process parameters in the turning of Aluminum Alloy 7075 using a Computer Numerical Control (CNC) machine. The optimal parameters influenced the rate of metal removal, the roughness of the machined surface, and the force of cutting. This experimental investigation deals with the optimization of speed (800 rpm, 1200 rpm, and 1600 rpm) and feed (0.15, 0.20, and 0.25 mm/rev) in addition to cutting depth (1.0, 1.5, and 2.0 mm) on the turning of Aluminum 7075 alloy in a CNC machine. The outcome in terms of results such as the removal rate of material (maximum), roughness on the machined surface (minimum), along with cutting force (least amount) were improved by the L27 array Taguchi method. There were 27 specimens of Al7075 alloy produced as per the array, and the corresponding responses were measured with the help of various direct contact and indirect contact sensors. Results were concluded all the way through diagrams of main effects in favor of signal-to-noise ratios and diagrams of surfaces with contour diagrams for various combinations of responses. [ABSTRACT FROM AUTHOR]

A lightweight, highly corrosive resistant, and high-strength wrought alloy in the aluminum family is the Aluminium 8006 alloy. The AA8006 alloy can be formed, welded, and adhesively bonded. However, the recommended welding methods such as laser, TIG (Tungsten Inert Gas welding), and ultrasonic are more costly. This investigation aims to reduce the cost of welding without compromising joint quality by means of friction stir welding. The aluminum alloy-friendly reinforcement agent zirconia is utilized as particles during the weld to improve the performance of the newly identified material AA8006 alloy in friction stir welding (FSW). The objectives of this research are to identify the level of process parameters for the friction stir welding of AA8006 to reduce the variability by the trial-and-error experimental method, thereby reducing the number of samples needing to be characterized to optimize the process parameters. To enhance the quality of the weld, the friction stir processing concept will be adapted with zirconia reinforcement during welding. The friction stir-processed samples were investigated regarding their mechanical properties such as tensile strength and Vickers microhardness. The welded samples were included in the corrosion testing to ensure that no foreign corrosive elements were included during the welding. The quality of the weld was investigated in terms of its surface morphology, including aspects such as the dispersion of reinforced particles on the welded area, the incorporation of foreign elements during the weld, micro defects or damage, and other notable changes through scanning electron microscopy analysis. The process of 3D profilometry was employed to perform optical microscopy investigation on the specimens inspected to ensure their surface quality and finish. Based on the outcomes, the optimal process parameters are suggested. Future directions for further investigation are highlighted. [ABSTRACT FROM AUTHOR]